Connector for insulated conductors

ABSTRACT

A connector for electrically joining insulated conductors without removing the insulation therefrom. The connector is a generally channel shaped metal member with a plurality of protuberances struck from and extending inwardly from opposed walls thereof, said protuberances being inclined away from adjacent ends. The channel member has a covering layer or jacket of electrically non-conducting material which extends over certain edges for sealing engagement, said jacket preventing contact of the metal portions of the connector with other electrical conducting material. The connector receives conductors between the walls and in response to crushing force thereon the protuberances penetrate insulation of the conductors and curve away from adjacent ends of the connector to hold the conductors and make electrical contact with the wires therein. The crushing provides a crimp whereby the walls remain in the conductor engaging position. A flowable plastic or like material filling the interior of the connector forms a substantially solid encapsulation of the electrical connections of the conductors and connector member to provide an air and moisture tight structure for protection against atmospheric conditions.

United States Patent [191 Neale, Sr. I

[ .lune 4, i974 1 1 CONNECTOR FOR INSULATED CONDUCTORS [75] lnventor:Dory J. Neale, Sr., St. Petersburg,

Fla.

[73] Assignee: National Telephone and Supply Co., Cleveland, Ohio [22]Filed: July 17, 1972 [2]] Appl. No.: 272,391

Related US. Application Data [63] Continuation-impart of Ser No.181,649, Sept. 20,

1971, abandoned.

Primary Examiner-Darrell L. Clay A Attorney, Agent, or Firm-Fishburn,Gold & Litman 5 7 ABSTRACT A connector for electrically joininginsulated conductors without removing the insulation therefrom. Theconnector is a generally channel shaped metal memher with a plurality ofprotuberances struck from and extending inwardly from opposed wallsthereof, said protuberances being inclined away from adjacent ends. Thechannel member has a covering layer or jacket of electricallynon-conducting material which extends over certain edges for sealingengagement, said jacket preventing Contact of the metal portions of theconnector with other electrical conducting material. The connectorreceives conductors between the walls and in response to crushing forcethereon the protuberances penetrate insulation of the conductors andcurve away from adjacent ends of the connector to hold the conductorsand make electrical contact with the wires therein. The crushingprovides a crimp whereby the walls remain in the conductor engagingposition. A flowable plastic or like material filling the interior ofthe connector forms a substantially solid encapsulation of theelectrical connections of the conductors and connector member to providean air and moisture tight structure for protection against atmosphericconditions.

116 Claims, 21 Drawing Figures PATENTEDJuN 4:914

SHEU [If 4 CONNECTOR FOR INSULATED CONDUCTORS This invention relates toelectrical connectors for insulated conductors and more particularly toa connector which is generallychannel shape arid crimped on to insulatedwire, with members to penetrate'the insulation and make electricalcontact with the wire or core therein. This application is acontinuation-in-part of my US. Pat. application Ser. No. 181,849, filedSept. 20, 1971, now abandoned, which was a continuation-inpart of my US.Pat. application Ser. No. ll,904, filed Dec. 28, 1970, now abandoned,which was a continuation-in-part, of my US. Pat. application Ser. No.818,495, filed Apr. 23, 1969, now abandoned.

The principal objects of the present invention are to provide animproved connector adapted to be crimped on insulated electricalconductors to electrically join same; to provide such a connector thatis a unitary structure having a metal member of low electricalresistance with a plurality of spaced insulation penetratingprotuberances arranged to guide the wires and make electrical contacttherewith; to provide such a connector with a covering forming aninsulating sheath or jacket in surrounding relation to the connector toprevent circuit interfering contact with other structure when it isapplied-to conductors; to provide a splice type connector withprotuberances inclined relative to ends of the connector with theprotuberances adapted to be deformed and form a gripping engagementretai ning the conductor in the connector when crimped thereon;' toprovide such a connector with laterally spaced protuberances or teeththat guide the wire during crimping and avoids cutting of the wires; toprovide such a connector with a plurality of protuberances arranged toprovide multiple contact with each electrical wire to assure electricalsplice thereof; to provide such a connector that is easily crimped intoposition with ordinary tools such as pliers or the like; to provide sucha connector'wherein a flowable plastic or like material is injected intothe interior to substantially fill all the voids and form a seal-againstair and moisture; to provide such a connector wherein the flowablematerial forms a solid encapsulating of the electrical connections ofthe conductors and connector to provide protection against moisture anddeleterious actions and oxidation and corrosion resulting therefrom; andto provide an electrical connector for joining insulated conductorsthatis economical to manufacture, is in a unitary structure that is easilyhandled, and that is quickly and efficiently crimped on to insulateconductors' for forming a positive, permanent, electrical connectiontherewith Other objects and advantages of this invention will becomeapparent from the following description taken in connection with theaccompanying drawings wherein are set forth by way of illustration andexam ples certain embodiments of this invention.

FIG. 1 is a perspective view of a connector of this invention crimped oninsulated conductors.

FIG. 2 is an enlarged plan view of the metal member before it is finallyformed and disclosing the arrangement of the protuberances thereon.

FIG. 3 is an end elevation of the metal member of FIG. 2 with theinsulating cover applied thereto.

FIG. 4 is an end view of the connector shaped for application toinsulated connectors.

. FIG. 5 is a longitudinal sectional view through the connector taken onthe line 5-5, FIG. 4.

FIG. 6 is a transverse sectional view through the connector withinsulated conductors positioned therein prior to crimping.

FIG. 7 is a transverse sectional view similar to FIG. 6 with theconnector crimped onto the insulated conductors.

FIG. 8 is a longitudinal sectional view through the crimped connectortaken on theline 8-8, FIG. 7.

FIG. 9 is an end elevational view of a modified form of connector withan additional crimp to maintain engagement with the insulated conductorstherein.

' FIG. i0 is an enlarged plan view of a modified metal member beforebeing finally formed and disclosing the arrangement of protuberancesthereon and apertures therethrough to create a plane of weakness forcrimping same to form a connector.

' FIG. 11 is a transverse sectional view showing the modified metalmember crimped onto insulated conductors.

FIG. 12 is a transverse sectional view showing'an additional crimp tomaintain engagement with the insulated conductors therein.

FIG. 13 is a perspective view of the modified metal member crimped toform the connector and having portions of an insulating. jacket removedto show the apertures through the modified metal member.

FIG. 14 is a perspective view of a further modified form of connectorcrimped on insulating conductors with the open side closed by portionsof an insulating jacket. j '1 FIG. 15 is a plan view of the metal memberand insulating jacket of said further modified form of connection.

. FIG. 16 is an end elevation of the connection of FIG. 14 formed toreceive conductors therein.

, FIG. 17 is an end elevation of the connection of FIG. 14 crimped tomaintain engagement with insulated conductors therein.

FIG. 18 is an end elevation of the connector and conductors shown. inFIG. 14 and showing the insulating jacket closing the open side of theconnector.

FIG. 19 is a perspective view of a form of connector on insulatedconductors with portions broken away to show the protective materialaround the metal electrical connections. t

FIG. 20 is a. transverse sectional view through the connection taken onthe line 20-20, FIG. l9.

FIG. 21 is a transverse sectional view through the connector on the line21-21, FIG. 19.

Referring more in detail to the drawings:

The reference numeral ll generally designates'a connector electricallyconnecting two or more insulated conductors 2 and securing same relativethereto. The connector I comprises two components, namely, an innermember or liner 3 formed of brass or other conductive metal, and aninsulating jacket 4 preferably of a film such as Mylar (polyetheleneterephthalate) suitable bonded to certain surfaces of the liner to forman external covering thereof.

The liner 3 has a plurality of sets 5 of spaced protuberances or teeth 6extending from the inner surface 7 and arranged with edges or portions 8for penetrating the insulation 9 of the conductors 2 and engaging a wirecore 10 thereof in connecting the conductors as later described. It ispreferred that the protrusions or teeth extend inwardly from the innersurface 7 at an angle thereto with the teeth or protuberances forengaginga conductor being inclined away from an end 11 of the liner ortoward the free end of a conductor to be engaged by said protuberances.While the number of adjacent end 11. While the connector may beforconnecting conductors extending only from one end, the structureillustrated shows sets of teeth arranged relative to both ends 11 and11' and is thereby adapted to receive conductors extending from bothends.

The liner is formed from a flat strip 15 of suitable metal such asphosphor-bronze or the like, and is then formed whereby theprotuberances 6 are struck up therefrom providing a perforation 16between a pair 17 of sets of protuberances, with all of the teeth of thepair of sets forming an obtuse angle 18 with the wall and extendingtherefrom. In the illustrated structure, there are a row of spacedperforations 16 adjacent the edge 21 of the strip. The protuberances atthe perforations toward the end 11 are inclined away from said end ortoward end 11'; and the protuberances at the perforations toward theend11' are inclined in the opposite direction or toward the end 11, but atthe'same angle relative to the wall. There is also a row ofprotuberances adjacent the edge 25 that correspond to the structure andformation of the protuberances of the pairs adjacent the edge 21,however, the protuberances of each set adjacent the edge 25 are offsetwhereby the free edges or ends 26 are substantially equally spaced fromthe free edges 27 of the protuberances of the opposed wall when thestrip is formed in a channel shape. Also, the sets'of protuberances orteeth adjacent the edge 25 are inclined away from the adjacent end edgesof the liner with the same angular relation to the wall as thoseadjacent the edge 21.

Each set of .protuberances consist of a plurality of transverselyaligned teeth and it is preferred that the free edges have a straightend edge portion 28 with angledor beveled portions 29 at each endthereof terminating in side edges 30. The side edges of adjacent teethhave a spacing slightly less than the diameter of the core of wire of aconductor to be connected and the beveled portions 29 cooperate to formrecesses 31 to receive the insulated conductor therebetween. As forexample, with an insulated conductor having core or wire of a diameterof approximately 0.019 of an inch, this spacing between side edges 30 ofadjacent teeth preferably would be in the nature of 0.015 of an inch.The teeth 6 of one row are substantially aligned with the other teeth ofthe connector for engaging a conductor so the spaces between the teethand the beveled portions forming the recessions make a path forreceiving the conductor and positioning same before compression. v

After the forming of the protuberances on the strip 15 as illustrated inFIG. 2,'a suitable insulating film of Mylar or the like is adhered tothe surface 32 of said strip by suitable adhesive preferably a heatcuring adhesive. The-film 4 has a greater width than the strip wherebyside margins 33 are turned up andinwar'dly to overlie the inner surface7 of the wall portions 13 and 14 and are adhered thereto. The coveredstrip is then bent to provide longitudinal bends as at 34 and 35 wherebythe walls 13 and 14 are substantially parallel and the structure of theliner and covering is substantially channel shape with the protuberances6 from the opposed walls spaced sufficiently whereby conductors 2 can beinserted therebetween, as illustrated in F IG. 6. With the conductors inplace, the connector is positioned between jaws of a suitable tool andforce is applied to the walls 13 and 14 to move same toward theconductor. The shape of the protuberances causes the conductor to be inthe recesses between the teeth and as the walls 13 and 14 are movedtoward each other the protuberances or teeth penetrate the insulation ofthe conductors so that the wire 10 moves between adjacent edges 30 withsaid edges penetrating the wire slightly to forma positive engagementtherewith. The inclination of the protuberances as shown in FIG. 5 issuch that as the walls 13 and 14 move toward each other the opposedteeth may engage each other or the opposed wall and then curve or bendin a manner tending to pull the conductor further into the liner, andalso to form a bite on the insulation and wire therein so as topositively hold the conductor 2 and wire 10 to make the electricalconnection. The position of the walls and protuberances when thecompression is completed is shown in FIGS. 7 and 8. This compression ofthe connector forms a clamping of the insulation and an engagement thattends to hold the structure in an intermeshed relation to prevent springback. The space be tween the side edges of adjacent teeth in the setshaving the greater distance from the ends of the connector may be lessto provide more bite into the wire and thereby a firm anchorage thereof.

In using a connector constructed as shown and described to spliceconductors, and with the connector in a channel shape as shown in FIG.4, two conductors may be inserted into the end 11 of the connector andmoved longitudinally thereof. The conductors will move through therecesses formed by adjacent teeth ends and be positioned therebetween.Then force is applied to the opposed walls 13 and 14 to compress thestructure forcing the conductors between the teeth which penetrate theinsulation and bite into the metal core making an electrical contacttherewith. Also the compression tends to flatten the structure so theteeth bend or curve back toward the wall from which they extend. Thisbending or curvature of the teeth forms an intermeshing that secures theconductors in place and prevents opening or spreading apart of the walls13 and 14. Also in the compression the margins of the jacket on theinside of the walls 13 and 14 are forced together forming aseal so thejacket acts as an insulating sleeve around the metal liner. This form ofsplicing is usable whenthe conductors extend into the connector from oneend. i

If it is desired to have conductors extend into the connector from bothends, as for example, in splicing four wires, the conductors'are movedinto the connector and supported by the teeth in the sets toward theends from which the conductors enter. Then the connector is compressedand makes electrical contact and hold the wires in the same manner aswhen they extend in from only one end. 2

in the form of the invention illustrated in FIG. 9, the structure of theliner and jacket 4 is the same as illustrated and described relative toFIGS. 1 to 8, inclusive, however, the structure of F IG. 9 isparticularly adapted for use with hard spring. like, material such, asspring tempered phosphor-bronze or the like, and after the clampingaction to move the structure in position as illustrated in FIGS. 7 and8, the fold or bend 39 in the web 12 is further crimped as at 40 tocrush the portions 41 and 42 together making a relative sharp bend inthe metal and this extra crimp aids in holding the walls and protrusionsin the compressed position and electrical engagement with the'wires ofthe conductors 2 and prevent any spring back.

It is preferred that the connector have a metal liner that is relativelyhard and such material has some spring back after bending, and alsorequires considerable force to forman effective crimp to hold theconnector in conductor connecting position. In the form of the inventionillustrated in'FIGS. 10to 13, inclusive, a modified connector 50 permitscrimping with less force and substantially eliminates spring back. Inthis structure, an inner member or liner 51 is formed of hard brass orother conductive material. The liner 51 is substantially the same shapeas the liner 3, shown in FIG. 2, and has the same sets of protuberancesorteeth 6 formed and inclined the same as the structure illustrated inFIGS. 2 and 3. j r

In the structure shown in FIGS. 10 to 13, inclusive, the portionscorresponding to the structure shown in FIGS. 1 to 9, inclusive, will beindicated by corresponding reference numerals. To facilitate crimping,the liner 51 has a line of weakness 52 extending longituidnally -in theweb portion .12 midway between the wall portions 13 and 14. This line ofweakness may be of any suitable form, as for example, a portion ofreduced thickness or a plurality of perforations longitudinally spacedalong the line. In the illustrated structure, the line of weakness isthe plurality of longitudinally spaced aligned elongateslots' 53extending through the mid portions of the web 12. The slots are of suchlength that the solid portions 54 between adjacent ends will havesufficient strength when the structure is crimped to hold the assemblyin the formed position. a

The connector 50 has a liner provided with 'an insulating jacket orcover'4 formed of a film bonded to the surfaces of the liner, and saidfilm is continuous over any openings'including the slots 53,Iwherebyit'forms an external covering for the metal liner. The modifiedconnector 50 with the covered metal liner is bent at the web portion toform a generally U-shaped structure, and when conductors 2 are placedbetween the protuberances or teeth 6, the walls 13 and 14 are movedtoward each other whereby the protuberances penetrate the insulation 9and engage the wire cores 10 to make the electrical connection, thestructure being substantially in the form shown in FIG. 11. Then, tohold the connector with the protuberances engaging the wire, the'web 12is crimped by bending same at the line of weakness 52 where by theadjacent wall portions 55 and 56 are moved substantially to face-to-facecontact, as illustrated in FIG. 12. This bending is a positive crimpwherein the web portion is crushed and bent beyond the elastic limit ofthe material of the inner member 51 so there is no spring back, andtheprotuberances or teeth 6 anchor the conductors 2 and maintain aconductor connecting position.

The force for crimping the connector as described due to the line ofweakness is such that it can be easily done with hand tools even thoughthe liner metalis of a hard metal.

7 6 One of the uses of the connector illustrated and described herein isthe splicing or connecting of telephone wires. It is common practice tohave a large number of wires in a cable or conduit as for example 200 to3,000 or more wires. In installation or in repair of breaks the wireshave portions extending from open ends of a two cable portion and thewires from one are connected to respective wires of the other tocomplete individual circuits. After completion of the connections alarger enclosure or sleeve is placed over the connections and adjacentends of the cables to provide weather protection for the connectedwires. Some of the connectors are spaced longitudinally of the wiresfrom other connectors, however, due to the large number there are manyconnectors that touch or may touch other connectors. If metal objects ormetal portions of a connector contact metal portions of anotherconnector or its respective conductors, circuit interference may result.This may cause interruption of service and cost in locating andrepairing the difficulty.

In the form of the invention illustrated in FIGS. 14 to 18 inclusive, amodified form of connector 60 provides an insulating protection againstforeign objects or members entering and contacting the metal member orconductors connected by the connector.

In the structure shown in FIGS. 14 to 18 inclusive, the portionscorresponding to the structure shown in FIGS. 1 to 13 inclusive, will beindicated by correspending-reference numerals. The connector 60 has aninsulating jacket or cover sheet 61 of an electrical nonconductingmaterial preferably of a film such as Mylar (polyethelene terephthalate)suitably bonded to the outer surface 62 of the metal member or liner 51.The cover sheet 61 has a length and width greater than the liner 51whereby margins 63 extend outwardly beyond edges at the ends 11 and 11'of the liner and margins 64 and 65 extend outwardly beyond the sideedges 21 and 25 of the liner 51. The cover sheet 61 is continuous overany openings in the liner and is impervious forming an externalinsulating covering for the metal liner.

The connector 60 with the covered liner 51 is bent to form a generallyU-shaped structure FIG. 16, with protuberances or teeth 6 positioned toreceive therebetween insulated conductors to be connected. In this shapeof the connector the margins 64 and 65 of the cover extend out from theside edges 21 and 25 in spaced apart relation whereby conductors to beconthe wire cores 10. It is desirable to have the metal por- I tions ofthe connector protected against contact with other connectors or othermetal objects that might cause circuit interference. The overhangingmargins 63 of the cover sheet 61 at ends of the connector provide anarrowed space that with the insulation 9 on the conductors 2 tend toprevent interfering contact. The sideopening 66 presents moredifficulty-as it is more accessible. The margins 64 and 65 tend toprevent entry of other objects, but to insure closure and protectionportions 67 of the walls 13 and 14 adjacent the edges 21 21 inclusive, afurther modified form of connector 70 a substantial encapsulation of thecontacting portions of the wire 10 of the conductors and the edges 30of'thc protuberances 6 to exclude moisture and air and thereby preventcorrosion.

In the structure shown in FIGS. 19 to 21 inclusive, the portionscorresponding to the structure shown in FIGS. 1 to 18 inclusive, will beindicated by corresponding reference numerals. The connector 70 has aninsulating jacket or cover sheet 71 preferably of film such as Mylarsuitably bonded to the outer surface 62 of the metal member or liner 51.With the conductors 2 positioned in the connector and the walls 13 and14 move toward each other and the protuberances penetrating theinsulation 9 and making electrical connection with the cores 10 of theconductors and the connector crimped as shown in H0. 17 on theedges 21and 25 of the walls 13 and 14 substantially close the side opening 66.The margins 74 and 75 of the cover sheet 61 engage and form a sideclosure. However, the

ends 76 and 77 f the structure are open. A filling 78 of a viscous orjelly-like material is applied to the interior of the connector tosubstantially fill the interior and particularly surround all metaliccontacting points with the wires of the conductors. The filling 78 maybe 'of any suitable non-conductor material that is viscous orjelly-like, 'whereby it may be injected into the interior of theconductor andwill remain in place during setting o'r curing to'a pliableplastic or solid that will encapsulate electrical connections. Suitablematerials for the filling are synthetic resins that will cure at roomtemperatures, such as epoxy resin and other thermo setting resins. Also,insulating putties and the like may be used.

In the structure illustrated the cover sheet 71 has an aperture 79arranged to align with a perforation 16 between a pair 17 of sets ofprotuberances; this provides a communication with the interior of theconnector whereby the filling may be applied through a suitable nozzlethrough. the opening 79 and perforation 16 to the central portion of theinterior ofthe connector. In this manner the filling may flow laterallyto the side edges 21 and 25 and to the web 12' and also toward both openends to substantially the ends of the walls 13 and 14. After completingthe filling the nozzle is removed and upon-setting of the filling thereis a substantially permanent connection of the conductors that isprotected against corrosion and circuit interference by electricalshorts.

While the disclosed embodiments of the invention are particularlyadapted to make a splice for up to four wires it will be apparent thatthe principal of an arrangement of the portions is equally applicable toother connectors for different numbers of wires and variations inarrangement and still provide for penetrating the insulation and makingelectrical contact with the wire. j

1 claim:

1. An electrical connection of conductors having insulation thereoncomprising:

a. a generally channel-shaped metal member having a web and opposedspaced apart walls extending therefrom;

b. rows of conductor engaging protuberances on said spaced walls withsaid rows arranged transversely thereof;

c. conductors having insulation thereon with portions positioned betweensaid walls;

d. said rows of protuberances each having a plurality of saidprotuberances with a spacing between adjacent protuberances receivingsaid conductor therebetween with the adjacent edges of the protuberancesbeing spaced less than the width of said conductor and engaging same;

e. an imperforate cover sheet of electrical nonconductive material onouter surfaces of said web and walls in covering relation thereto; and

f. said conductors being clamped between the walls of saidchannel-shaped member and said protuberance edge penetrating into theinsulation of said conductors therebetween and said protuberancescurving away from an adjacent end of the channelshaped member to holdsaid conductor and make electrical contact therewith.

2. An electrical connection as set forth in claim 1 wherein the rows ofprotuberances in one wall are offset from the rows in the other wallwith a row of protuberances in one wall being substantially betweenadjacent rows of protuberances in the other wall.

3. An electrical connection as set forth in claim 2 wherein:

a. the rows of protuberances are in pairs struck inwardly from thespaced walls; and

b. said protuberances of each pair of rows being inclined toward theopposed wall and away from the adjacent end of the channel-shapedmember.

4. An electrical connection as set forth in claim 3 wherein:

a. each opposed wall of the channel-shaped member has a plurality ofrows of protuberances with protuberances of rows in one end portioninclined toward the protuberances of rows in the other end portion; and

b. each row having a plurality of protuberances and a plurality ofspaces therebetween receiving at least two of said conductors extendingfrom an adjacent end of the connector with each of said conductors beingengaged by edges of two adjacent protuberances in the respective rows.

5. An electrical connection as set forth in claim 4 wherein thechannel-shaped member having the web connecting the walls at one sidecrushed to crimp the channel-shaped member to hold the protuberances inconductor engaging position.

6. An electrical connection as set forth in claim 1 and including:

a..said rows of protuberances being formed in said metal member withopenings between certain adjacent rows;

b. said imperforatc cover sheet having an entrance opening therethroughcommunicating with the area having the conductor therein through anopening between rows of protuberances in the metal member; and

c. a setable semi-solid filler inserted through said entrance openingand surrounding all electrical connections between said metal member andthe electrical conductors to encapsulate same.

7. An electrical connection as set forth in claim 1 wherein said web hasa line of weakness extending longitudinal thereof and crushing of thechannel-shaped member along said line of weakness bends the web on saidline and the wall portions adjacent said line are in substantiallyface-to-face contact.

8. An electrical connection as set forth in claim 7 wherein the line ofweakness is a plurality of longitudinally aligned slots extendingthroughthe metal member.

9. An electrical connection as set'forth in claim 7 wherein:

a. said channel-shaped metal member has side and b. said imperforatecover sheet has marginal portions extending outwardly beyond the end andside edges of said metal member and forming an overhanging insulatingprotector from circuit interferring contact of said metal member andconductors with foreign objects. v

10. An electrical connection as set forth in claim 9 wherein:

a. said spaced apart walls having portions adjacent said side edgesbeing bent one toward the other whereby the marginal portions extendingbeyond said side edges are engaged and close and form an insulatingclosurefor said side opening. j

11. An electrical connector as set forth in claim 10 and including:

a. a filling of setable material in the metal member encapsulating theareas of electrical engagement and protecting same against moisture andair, said setable material being introduced after completion of theconnection of the connector metal member with the conductors.

12. An electrical connection as wherein:

a. said imperforate cover sheet has marginal portions extendingoutwardly beyond side and end edges of said channelshaped metal memberand form an insulating protector of said metal member from circuitinterfacing contact with foreign objects.

13. An electrical connection as set forth in claim 1 wherein:

a. said channel-shaped metal member has side and end edges with saidside edges defining a side openmg;

b. said imperforate cover sheet has marginal portions extendingoutwardly beyond said side edges;

c. said spaced apart walls of said channel-shaped metal member havingportions adjacent said side edges being bent one toward the other andthe marginal portions of said cover sheet being engaged to close saidside opening and form an insulating protector from circuit interferringcontacts.

14. An electrical connection of insulated electrical conductorscomprising, a generally channel-shaped metal member having'a web andopposed spaced apart walls extending therefrom, rows of conductorengaging edges on said spaced walls with said rows arranged transverselythereof, said rows of edges on one wall set forth in claim 1 shapedmember and from an end thereof, said conduc-' tors being engaged bycertain of said rows of edges, each of said rows being inclined at anacute angel with respect to its respective walland away from the end ofthe channel-shaped member from which the respective conductors engagedthereby extends, an imperforate cover sheet of electrical non-conductivematerial on outer surfaces of said web and walls in coveringrelationship thereto, said insulated conductors being clamped betweensaid walls of the channel-shaped members with said edges penetratinginto the insulation of the conductors and into engagement with theconductor and said edges curving away from an adjacent end of the saidchannel-shaped member from which the respective engaged conductorextends to hold said conductor and make electrical contact therewith.

15. An electrical connection of conductors having insulation thereoncomprising:

a. a generally channel-shaped metal member having a web and opposedspaced apart walls extending therefrom;

b. rows of conductor engaging protuberances on said spaced walls withsaid rows arranged transversely thereof;

c. conductors having insulation thereon with portions positioned betweensaid walls, said conductors extending longitudinally of saidchannel-shaped member and from an end thereof;

(i. said rows of protuberances each having a plurality of saidprotuberances with a spacing between adjacent protuberances receivingsaid conductors therebetween with adjacent edges of the protuberancesbeing spaced less than the width of the conductor and engaging same;

e. the rows of protuberances are in pairs struck inwardly from thespaced walls;

f. said protuberances of each pair of r'owsbeing inclined toward theopposed wall and away from the adjacent end of the channel-shapedmember;

g. an imperforate cover sheet of electrical nonconductive material onouter surfaces of said web and walls in covering relation thereto;

h. the channel-shaped member has said web portion connecting the opposedwalls at one side thereof;

i. said conductors being clamped between the walls of saidchannel-shaped member and adjacent protuberance edges penetrating intothe insulation of said conductors therebetween and said protuberancescurving away from an adjacent end of the channel-shaped member to holdthe conductor and make electrical contact therewith; and

j. said web being further crushed and bent beyond the elastic limit ofthe material to hold the walls and the protuberances thereon inconductor connecting position.

16. An electrical connection as set forth in claim 15 wherein said webhas a plurality of longitudinally aligned slots extending through themetal member and defining a line of weakness substantially midwaybetween the spaced walls and the crushing and bend of the web is alongsaid line with adjacent wall portions in substantially face-to-facecontact.

1. An electrical connection of conductors having insulation thereon comprising: a. a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom; b. rows of conductor engaging protuberances on said spaced walls with said rows arranged transversely thereof; c. conductors having insulation thereon with portions positioned between said walls; d. said rows of protuberances each having a plurality of said protuberances with a spacing between adjacent protuberances receiving said conductor therebetween with the adjacent edges of the protuberances being spaced less than the width of said conductor and engaging same; e. an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relation thereto; and f. said conductors being clamped between the walls of said channel-shaped member and said protuberance edge penetrating into the insulation of said conductors therebetween and said protuberances curving away from an adjacent end of the channelshaped member to hold said conductor and make electrical contact therewith.
 2. An electrical connection as set forth in claim 1 wherein the rows of protuberances in one wall are offset from the rows in the other wall with a row of protuberances in one wall being substantially between adjacent rows of protuberances in the other wall.
 3. An electrical connection as set forth in claim 2 wherein: a. the rows of protuberances are in pairs struck inwardly from the spaced walls; and b. said protuberances of each pair of rows being inclined toward the opposed wall and away from the adjacent end of the channel-shaped member.
 4. An electrical connection as set forth in claim 3 wherein: a. each opposed wall of the channel-shaped member has a plurality of rows of protuberances with protuberances of rows in one end portion inclined toward the protuberances of rowS in the other end portion; and b. each row having a plurality of protuberances and a plurality of spaces therebetween receiving at least two of said conductors extending from an adjacent end of the connector with each of said conductors being engaged by edges of two adjacent protuberances in the respective rows.
 5. An electrical connection as set forth in claim 4 wherein the channel-shaped member having the web connecting the walls at one side crushed to crimp the channel-shaped member to hold the protuberances in conductor engaging position.
 6. An electrical connection as set forth in claim 1 and including: a. said rows of protuberances being formed in said metal member with openings between certain adjacent rows; b. said imperforate cover sheet having an entrance opening therethrough communicating with the area having the conductor therein through an opening between rows of protuberances in the metal member; and c. a setable semi-solid filler inserted through said entrance opening and surrounding all electrical connections between said metal member and the electrical conductors to encapsulate same.
 7. An electrical connection as set forth in claim 1 wherein said web has a line of weakness extending longitudinal thereof and crushing of the channel-shaped member along said line of weakness bends the web on said line and the wall portions adjacent said line are in substantially face-to-face contact.
 8. An electrical connection as set forth in claim 7 wherein the line of weakness is a plurality of longitudinally aligned slots extending through the metal member.
 9. An electrical connection as set forth in claim 7 wherein: a. said channel-shaped metal member has side and end edges with said side edges defining a side opening at the other side of the web of said member; and b. said imperforate cover sheet has marginal portions extending outwardly beyond the end and side edges of said metal member and forming an overhanging insulating protector from circuit interferring contact of said metal member and conductors with foreign objects.
 10. An electrical connection as set forth in claim 9 wherein: a. said spaced apart walls having portions adjacent said side edges being bent one toward the other whereby the marginal portions extending beyond said side edges are engaged and close and form an insulating closure for said side opening.
 11. An electrical connector as set forth in claim 10 and including: a. a filling of setable material in the metal member encapsulating the areas of electrical engagement and protecting same against moisture and air, said setable material being introduced after completion of the connection of the connector metal member with the conductors.
 12. An electrical connection as set forth in claim 1 wherein: a. said imperforate cover sheet has marginal portions extending outwardly beyond side and end edges of said channel-shaped metal member and form an insulating protector of said metal member from circuit interfacing contact with foreign objects.
 13. An electrical connection as set forth in claim 1 wherein: a. said channel-shaped metal member has side and end edges with said side edges defining a side opening; b. said imperforate cover sheet has marginal portions extending outwardly beyond said side edges; c. said spaced apart walls of said channel-shaped metal member having portions adjacent said side edges being bent one toward the other and the marginal portions of said cover sheet being engaged to close said side opening and form an insulating protector from circuit interferring contacts.
 14. An electrical connection of insulated electrical conductors comprising, a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom, rows of conductor engaging edges on said spaced walls with said rows arranged transversely thereof, said rows of edges on one wall being offset with respect to the rows of edges on the other wall with a row of said edges on one wall being substantially between adjacent rows of edges on the other wall, insulated conductors positioned between said walls and extending longitudinally of said channel-shaped member and from an end thereof, said conductors being engaged by certain of said rows of edges, each of said rows being inclined at an acute angel with respect to its respective wall and away from the end of the channel-shaped member from which the respective conductors engaged thereby extends, an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relationship thereto, said insulated conductors being clamped between said walls of the channel-shaped members with said edges penetrating into the insulation of the conductors and into engagement with the conductor and said edges curving away from an adjacent end of the said channel-shaped member from which the respective engaged conductor extends to hold said conductor and make electrical contact therewith.
 15. An electrical connection of conductors having insulation thereon comprising: a. a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom; b. rows of conductor engaging protuberances on said spaced walls with said rows arranged transversely thereof; c. conductors having insulation thereon with portions positioned between said walls, said conductors extending longitudinally of said channel-shaped member and from an end thereof; d. said rows of protuberances each having a plurality of said protuberances with a spacing between adjacent protuberances receiving said conductors therebetween with adjacent edges of the protuberances being spaced less than the width of the conductor and engaging same; e. the rows of protuberances are in pairs struck inwardly from the spaced walls; f. said protuberances of each pair of rows being inclined toward the opposed wall and away from the adjacent end of the channel-shaped member; g. an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relation thereto; h. the channel-shaped member has said web portion connecting the opposed walls at one side thereof; i. said conductors being clamped between the walls of said channel-shaped member and adjacent protuberance edges penetrating into the insulation of said conductors therebetween and said protuberances curving away from an adjacent end of the channel-shaped member to hold the conductor and make electrical contact therewith; and j. said web being further crushed and bent beyond the elastic limit of the material to hold the walls and the protuberances thereon in conductor connecting position.
 16. An electrical connection as set forth in claim 15 wherein said web has a plurality of longitudinally aligned slots extending through the metal member and defining a line of weakness substantially midway between the spaced walls and the crushing and bend of the web is along said line with adjacent wall portions in substantially face-to-face contact. 